Surface cleaning apparatus

ABSTRACT

A surface cleaning apparatus including a separator having an inlet for receiving dirt laden air and an outlet. The surface cleaning apparatus further includes a suction source and a chamber having an inlet in communication with the separator outlet and outlet in communication with the suction source. The chamber inlet and the chamber outlet are offset from each other.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. national stage entry of international patent application no. PCT/GB2014/050688, filed Mar. 7, 2014, the entire contents of which are hereby incorporated by reference.

BACKGROUND

This invention relates generally to a surface cleaning apparatus, e.g. suction cleaners.

Suction cleaners are well known appliances, utilising a suction airflow to draw dust and other matter from whatever is being cleaned. The airflow passes through a dust separator and collector wherein dust entrained in the suction airflow is separated from the airflow and retained for later disposal. For effective cleaning, a high rate of airflow is required. To create this a cleaner requires a powerful suction source in the form of a fan or impeller capable of creating the high airflow and a correspondingly-powerful electric motor to drive the fan. At present, it is not uncommon to find cleaners whose electrical power consumption is of the order of 1.5 kw to 2.0 kw, or possibly even higher.

One problem associated with such cleaners is that a high level of noise may be generated by the air flowing through the cleaner, and by the motor and fan which create the airflow. It is desirable, in particular for domestic use, that the noise emitted by a cleaner should be reduced as far as possible.

SUMMARY

Embodiments of the present invention seek to provide a surface cleaning apparatus that overcomes, or at least substantially reduces, the disadvantages associated with known cleaners.

According to one aspect of the invention, we provide a surface cleaning apparatus including:

-   -   a separator having an inlet for receiving dirt laden air and an         outlet;     -   a suction source; and     -   a chamber having:         -   an inlet in communication with the separator outlet; and         -   an outlet in communication with the suction source,     -   wherein the chamber inlet and the chamber outlet are offset from         each other.

The chamber inlet and the chamber outlet may be radially offset from each other, e.g. such that the chamber outlet is only partially visible through the chamber inlet when viewed through the chamber from the chamber inlet end.

According to a second aspect of the invention, we provide a surface cleaning apparatus including:

-   -   a separator having an inlet for receiving dirt laden air and an         outlet;     -   a suction source; and     -   a chamber having:         -   an inlet in communication with the separator outlet; and         -   an outlet in communication with the suction source,     -   wherein the chamber inlet and the chamber outlet are not         aligned.

According to a third aspect of the invention, we provide a surface cleaning apparatus including:

-   -   a separator having an inlet for receiving dirt laden air and an         outlet;     -   a suction source; and     -   a chamber having:         -   an inlet in communication with the separator outlet; and         -   an outlet in communication with the suction source,     -   wherein the chamber inlet and the chamber outlet are positioned         such that air is caused to change direction as it passes through         the chamber from the chamber inlet to the chamber outlet.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the various aspects of the invention will now be described by way of example only, with reference to the accompanying drawings, of which:

FIG. 1 shows a cut-away perspective view of a surface cleaning apparatus according to some embodiments;

FIG. 2 shows an exploded view of internal components of a surface cleaning apparatus according to some embodiments;

FIG. 3 shows an end view of internal components of a surface cleaning apparatus according to some embodiments;

FIG. 4 is a perspective view of an internal component of a surface cleaning apparatus according to some embodiments;

FIG. 5 is an alternative perspective view of the internal component of FIG. 4.

FIG. 6 shows a cross sectional view of internal components of a surface cleaning apparatus according to some embodiments; and

FIG. 7 shows an end view of internal components of a surface cleaning apparatus according to some embodiments.

DETAILED DESCRIPTION

With reference to FIG. 1, embodiments of the present invention include a surface cleaning apparatus, indicated generally at 1. The surface cleaning apparatus 1 includes a separator 10 having a separator inlet 101 for receiving dirt laden air from a surface to be cleaned, and a separator outlet 102. The surface cleaning apparatus 1 also includes a suction source 11. In some embodiments the suction source 11 may include an electric motor 110 and a fan 111, the fan 111 being driven by the electric motor 110 to cause air to be sucked from a surface to be cleaned and to draw the air towards the suction source 11 via the separator 10.

The separator 10 may be a cyclonic separator. FIG. 1 shows a multi-stage cyclonic separator, although some embodiments may include a single or a dual-stage cyclonic separator. Indeed, some embodiments may include other forms of dust collection such as a bag.

The surface cleaning apparatus 1 includes a chamber 12 located between the separator 10 and the suction source 11. The chamber 12 includes a chamber inlet 121 and a chamber outlet 122. The chamber inlet 121 is in communication with the separator outlet 102 and the chamber outlet 122 is in communication with the suction source 11. The chamber inlet 121 may be configured to receive air flowing from the separator outlet 102 via a duct 103. It is to be appreciated that the duct 103 does not itself form a part of the chamber 12, but rather provides a passage for air to flow between the separator 10 and the chamber 12.

Referring now to FIG. 2 there is shown an exploded view of the suction source 11 and the chamber 12. FIG. 2 also shows a housing, indicated generally at 13, details of which will be described below. The chamber 12 may include a first part 123 and a second part 124. The first and second parts 123, 124 are shown as separate parts that may be connectable, for instance by a grub screw, rivet or even by an interference or friction fit. In some embodiments, the first and second parts 123, 124 may be formed integrally as a single component. The chamber inlet 121 is formed in the first part 123 and the chamber outlet 122 is formed in the second part 124.

Significant levels of noise are generated when air flows in a direction aligned with the chamber outlet 122. As will be appreciated from FIGS. 2 and 3 the chamber inlet 121 and the chamber outlet 122 are radially offset from each other. Advantageously, this causes the flow of air to change direction as it passes through the chamber 12 from the chamber inlet 121 to the chamber outlet 122. By causing the flow of air to change direction as the air flows through the chamber 12 the inventors have discovered that the noise generated by the air flowing through the cleaner is significantly reduced.

In some embodiments the suction source 11 may be held within the housing 13. In some embodiments, the housing 13 may include an inner housing 131 and an outer housing 132. The suction source 11 may be held within the inner housing 131 and the inner housing 131 may be held within the outer housing 132. Some embodiments may include a further main body housing 133, in which the inner and outer housings 131, 132 are held.

The inner housing 131 may include an inner housing base 131 a and an inner housing lid 131 b. In some embodiments the inner housing base 131 a includes a wall 1310 having a generally cylindrical configuration. However, in other embodiments, the wall may be formed into a different shape such as a rectangle, triangle or other polygon. In some embodiments the wall 1310 may include an array of apertures 1311 (or means to permit air to flow through the wall 1310) provided in one side thereof. The suction source 11 may be held within the inner housing 131. In some embodiments mounts 14 a, 14 b (for instance, formed from a natural or synthetic rubber, such as silicone) may be provided at either end of the suction source 11 to absorb vibrations from the suction source 11 and to provide for noise reduction.

The outer housing 132 may include an outer housing base 132 a and an outer housing lid 132 b. In some embodiments the outer housing base 132 a includes a wall 1320 having a generally cylindrical configuration. However, in other embodiments, the wall may be formed into a different shape such as a rectangle, triangle or other polygon. In some embodiments the wall 1320 may include an array of apertures 1321 (or means to permit air to flow through the wall 1320) provided in one side thereof. Advantageously, the array of apertures 1321 are provided diametrically opposite from the array of apertures 1311 provided in the inner housing base 131 a. The inner housing 131 may be held within the outer housing 132. In some embodiments mounts (not shown) may be provided at either end of the inner housing 131 to further absorb vibrations from the suction source 11 and to provide for noise reduction.

The outer housing 132 may be held within a main body housing 133. In some embodiments mounts 15 a, 15 b (for instance, formed from a natural or synthetic rubber, such as silicone) may be provided at either end of the outer housing 132 to further absorb vibrations from the suction source 11 and to provide for noise reduction.

In some embodiments mount 15 a may be located adjacent to and in contact with the chamber 12.

In some embodiments, the mount 15 a may be at least partially housed within a cavity (not shown) in the second part 124 of the chamber 12. The inventors have discovered that in such embodiments the mount 15 a further deadens the sound of air flowing through the cleaner.

FIG. 4 shows the upstream face of the second part 124. In some embodiments the second part 124 may include a ridge 125 which partially surrounds the chamber outlet 122. In some embodiments the height of the ridge 125 may differ about its perimeter. The second part 124 may also include a ramped (or curved) surface 126 extending between the ridge 125 and the chamber outlet 122. It is to be appreciated that the extent to which the surface 126 is ramped (or curved) will depend upon the height of the ridge 125 at a particular location about its perimeter. In other words, the ramp angle (or degree of curvature) between the ridge 125 and the chamber outlet 122 will vary at different points around the perimeter of the ridge 125, depending on the height of the ridge 125 at that particular location. Advantageously, the surface 126 is aligned with the chamber inlet 121 (this is most clearly shown in FIG. 3) so as to receive the air as it passes through the chamber 12 and to cause the air to change direction as it flows towards the chamber outlet 122. As will be appreciated from FIGS. 1 and 3, the chamber inlet 121 is radially offset from the chamber outlet 122, such that the chamber outlet 122 is only partially visible when looking down the chamber 12 in the direction of arrow F.

In some embodiments the chamber outlet 122 may be partially occluded by a shield 127. The shield 127 may be spaced from the remainder of the second part 124 by spaced-apart legs 128 to provide a passage 129 a which permits air to flow through the chamber outlet 122 and towards the suction source 11. In some (but not necessary all) embodiments the second part 124 may also include an array of further apertures 129 b at least partially surrounding the passage 129 a. The array of further apertures 129 b may advantageously prevent a build-up of pressure in the chamber 12.

FIG. 5 shows the downstream face of the second part 124. In the illustrated embodiment the second part 124 includes a first series of parallel ribs 1240 extending from one side of the second part 124 to the other. The second part 124 also includes a second series of parallel ribs 1241 arranged orthogonal to the first series of parallel ribs 1240 and extending from one side of the second part 124 to the other. The ribs 1240, 1241 provide strength to the second part 124.

In some embodiments some or all of the ribs 1240, 1241 may not be present. In some embodiments a cavity (not shown) may be provided in the second part 124 for at least partially receiving the mount 15 a. As mentioned previously, the inventors have discovered that the mount 15 a further deadens the sound of air flowing through the cleaner when the mount 15 a is at least partially received in a cavity of the second part 124.

Operation of an embodiment will now be described by way of example only and with reference to the figures, particularly FIG. 1. Suction generated by the suction source 11 causes dirt-laden air to flow from a surface being cleaned and towards the separator 10 in the direction of arrows A and B. The dirt-laden air flows in the direction of arrow C into the separator 10 via the separator inlet 101, where the dirt is separated from the flow of air in a conventional manner. Air continues to flow in the direction of arrow D into a duct 103 via separator outlet 102 and through the duct 103 in the direction of arrow E.

Referring now to FIG. 2 the air flows into the chamber 12 via chamber inlet 121 in an axial direction indicated by arrow F. The airflow then contacts the surface 126 of the second part 124 which causes the air to change direction and flow in a direction substantially orthogonal to the axial direction indicated by arrow F and towards the chamber outlet 122. It is to be appreciated that by causing this gradual change in the direction of the airflow the noise that would have otherwise been generated by the air flowing towards the suction source 11 is significantly reduced. This results in a vacuum cleaner that is much quieter during use than a conventional cleaner.

In embodiments where the degree of curvature (or ramp angle) between the ridge 125 and the chamber outlet 122 varies at different points around the perimeter of the ridge 125, it is to be appreciated that the air will tend to flow circumferentially about the axial direction indicated by arrow F whilst flowing towards the chamber outlet 122. This has the effect of increasing the flow path between the chamber inlet 121 and the chamber outlet 122, which causes an even greater reduction in noise.

Since there is a partial overlap between the chamber inlet 121 and the chamber outlet 122 (as viewed most clearly in FIG. 3), the second part 124 is provided with a shield 127 that partially occludes the chamber outlet 122. It is to be understood that the shield 127 inhibits air flowing in the direction of indicated by arrow F from directly entering the chamber outlet 122, as this would generate significant levels of noise in doing so. Accordingly, all air flowing into the chamber 12 via the chamber inlet 121 is caused to change direction before flowing through the chamber outlet 122 and towards the suction source 11. The shield 127 is spaced from the remainder of the second part 124 by spaced-apart legs 128 to provide passages 129 a which permit air to flow through the chamber outlet 122 and towards the suction source 11. The passages 129 a are configured such that air flowing across the surface 126 (either in a direction substantially orthogonal to the axial direction indicated by arrow F or circumferentially around the axial direction indicated by arrow F) will flow to the suction source 11 without generating significant levels of noise.

The chamber inlet 121 is offset with respect to the chamber outlet 122 so that air is caused to change direction as it flows through the chamber 12 from the chamber inlet 121 to the chamber outlet 122. It is to be understood that air leaving the chamber 12 via the chamber outlet 122 flows towards the suction source 11 in the same direction as indicated by arrow F, but radially offset therefrom as indicated by arrow G.

With reference now to FIGS. 1, 6 and 7 the air flows through the fan 111 and is directed radially in the direction of arrow H and through the array of apertures 1311 located in the wall 1310 of the inner housing 131. The air then comes into contact with the inner wall 1320 of the outer housing 132 which is configured to direct the air circumferentially around the inner housing 131 as indicated by arrows HH and then radially in the direction of arrow I and through the array of apertures 1321 located in the wall 1320 of the outer housing 132. The air then comes into contact with an inner wall 1330 of the main body housing 133 which is configured to direct the air beneath the outer housing 132 in the direction of arrow J before being exhausted from the apparatus 1 via an exhaust filter 134 in the direction of arrow K.

By configuring the housing 13 in such a manner that the flow of air through the apparatus 1 is longer than it would have been otherwise, this has the effect of increasing the amount of contact between the air and the housing components, thereby causing the sound to deaden.

Of course, it is to be appreciated that whilst the illustrated embodiment shows the air first flowing circumferentially around the inner housing 131 before being configured to flow beneath the outer housing 132, some embodiments may be configured such that the air first flows beneath the inner housing 131 (i.e. between the inner and outer housings) and then circumferentially around the outer housing 132. Indeed, some embodiments may be configured such that the air first flows circumferentially around the inner housing 131 before being configured to flow circumferentially around the outer housing or even configured such that the first flows beneath the inner housing 131 and then beneath the outer housing 132 before being exhausted from the apparatus 1 via an exhaust filter 134 in the direction of arrow K. In all of these embodiments, however, the array of apertures 1311 in the wall 1310 of the inner housing 131 are configured to be diametrically opposite from the array of apertures 1321 in the wall 1320 of the outer housing 132.

The main body housing 133 may include an exhaust (post-suction source 11) filter 134. Whilst the separator 10 of the apparatus 1 may be effective at removing substantially all dust entrained in the suction airflow drawn from whatever is being cleaned, the brushes of the type of electric motor commonly used in vacuum cleaners may themselves cause some carbon dust to be created, and an exhaust filter 134 is effective at preventing such carbon dust (and any cleaning dust which might pass the separator 10) from being emitted to the external atmosphere. The exhaust filter 134 may comprise a filter element which is insertable and removable from the exhaust main body housing 133. The filter element may be accessible for removal and replacement from the exterior of the apparatus 1, and be removable from and replaceable into a formation in the body of the apparatus 1.

Whilst the drawings show a surface cleaning apparatus of the cylinder vacuum cleaner type, it is to be understood that in some embodiments the surface cleaning apparatus may be of the upright or hand-held types.

When used in this specification the term “upstream” is intended mean towards the end of the airflow path at which the dirt-laden air enters the apparatus, and the term “downstream” is intended to mean towards the end of the airflow path at which the air exits the apparatus.

When used in this specification and claims, the terms “comprises” and “comprising” and variations thereof mean that the specified features, steps or integers are included. The terms are not to be interpreted to exclude the presence of other features, steps or components.

The features disclosed in the foregoing description, or the following claims, or the accompanying drawings, expressed in their specific forms or in terms of a means for performing the disclosed function, or a method or process for attaining the disclosed result, as appropriate, may, separately, or in any combination of such features, be utilised for realising the invention in diverse forms thereof. 

1. A surface cleaning apparatus including: a separator having an inlet for receiving dirt laden air and an outlet; a suction source; and a chamber having: an inlet in communication with the separator outlet; and an outlet in communication with the suction source, wherein the chamber inlet and the chamber outlet are offset from each other.
 2. A surface cleaning apparatus according to claim 1, wherein the chamber inlet and the chamber outlet are radially offset from each other.
 3. A surface cleaning apparatus including: a separator having an inlet for receiving dirt laden air and an outlet; a suction source; and a chamber having: an inlet in communication with the separator outlet; and an outlet in communication with the suction source, wherein the chamber inlet and the chamber outlet are not aligned.
 4. A surface cleaning apparatus including: a separator having an inlet for receiving dirt laden air and an outlet; a suction source; and a chamber having: an inlet in communication with the separator outlet; and an outlet in communication with the suction source, wherein the chamber inlet and the chamber outlet are positioned such that air is caused to change direction as it passes through the chamber from the chamber inlet to the chamber outlet.
 5. A surface cleaning apparatus according to claim 1, wherein the chamber includes a part for changing the direction of airflow as the airflow passes through the chamber from the chamber inlet to the chamber outlet.
 6. A surface cleaning apparatus according to claim 5, wherein the part includes a ramped or curved surface.
 7. A surface cleaning apparatus according to claim 6, wherein the ramped or curved surface is substantially aligned with the chamber inlet when viewed through the chamber from the chamber inlet end, so as to cause the air to change direction as it passes through the chamber from the chamber inlet to the chamber outlet.
 8. A surface cleaning apparatus according to claim 1, wherein the chamber outlet includes an aperture which is partially occluded by a shield.
 9. A surface cleaning apparatus according to claim 8, wherein the chamber includes a part for changing the direction of airflow as the airflow passes through the chamber from the chamber inlet to the chamber outlet, and wherein the shield is spaced from the part by spaced-apart legs to provide a passage which permits air to flow from the part towards the suction source.
 10. A surface cleaning apparatus according to claim 9, wherein the chamber outlet includes an array of further apertures surrounding the passage.
 11. A surface cleaning apparatus according to claim 5, including a sound dampener located adjacent to the part.
 12. A surface cleaning apparatus according to claim 11, wherein the sound dampener is at least partially housed within a cavity of the part, the cavity being provided underneath the or a ramped or curved surface of the part.
 13. A surface cleaning apparatus according to claim 11, wherein the sound dampener is formed from rubber.
 14. A surface cleaning apparatus according to claim 5, wherein the part includes ribs for providing strength to the part.
 15. A surface cleaning apparatus according to claim 1, including: a first housing part; a second housing part; and a third housing part, wherein the suction source is held within the first housing part, wherein the first housing part is held within the second housing part, and wherein the second housing part is held within the third housing part.
 16. A surface cleaning apparatus according to claim 15, wherein the first housing part includes apertures formed in a wall thereof to permit air to flow from the first housing part and into the second housing part, and wherein the second housing part is configured such that the air then flows either: circumferentially around the first housing part; or beneath the first housing part.
 17. A surface cleaning apparatus according to claim 16, wherein the second housing part includes apertures formed in a wall thereof to permit air to flow from the second housing part and into the third housing part, and wherein the third housing part is configured such that the air then flows either: circumferentially around the second housing part; or beneath the second housing part.
 18. A surface cleaning apparatus according to claim 15, wherein the third housing part includes an exhaust air filter.
 19. A surface cleaning apparatus according to claim 1, wherein the suction source includes an electric motor in driving connection with an airflow-creating fan.
 20. A surface cleaning apparatus according to claim 1, wherein the separator is a cyclonic separator.
 21. A surface cleaning apparatus according to claim 1, wherein the apparatus is a cylinder vacuum cleaner an upright vacuum cleaner, or a hand-held vacuum cleaner. 22.-25. (canceled) 